Pant-type absorbent article and manufacturing method thereof

This application claims priority to Chinese PCT Patent Application No. PCT/CN2020/104295, filed on Jul. 24, 2020 and to Chinese PCT Patent Application Serial No. PCT/CN2020/077152, filed on Feb. 28, 2020, both of which are incorporated by reference herein.

The present invention relates to pant-type absorbent articles having a protective measure for preventing leakage of low viscosity bodily exudates, while also maintaining other functions as a pant-type wearable article. The present invention also relates to methods of manufacturing such pant-type absorbent articles.

Infants and other individuals wear absorbent articles such as diapers to receive and contain urine and other body exudates. Pull-on absorbent articles, or pant-type absorbent articles, such as described in PCT Publication WO 2006/17718 A, are those which are donned by inserting the wearer's legs into the leg openings and sliding the article up into position about the lower torso. Pant-type absorbent articles have become popular for younger babies requiring a soft fit around the waist opening and leg openings. Pant-type absorbent articles have also become popular for females having heavy flow or overnight usage during menstruation periods. One function desired for a pant-type article is a protective measure for preventing leakage of low viscosity bodily exudates through the waist opening. Those pant-type articles having less material around the waist opening for breathability purpose or otherwise, may have risk of leakage from the waist opening, particularly when the wearer is lying on his/her back or belly.

Pant-type articles may take various structures wherein the circumference of the waist opening and vicinity thereof is made elastic enough to facilitate the wearer or the caregiver to expand the article and insert the wearer's legs into the leg openings for wearing the article. Accordingly, pant-type articles provide only a very small range of size adjustment or body configuration adjustment based on the structural limitations of the article. As such, pant-type articles are typically so configured to accommodate size and configuration ranges by providing the elastic belt region very stretchable and comfortable to wear, yet with reliable fit such that sufficient protection against sagging and leakage may be provided. It is desired that such basic functions of the elastic belt region may be maintained even with introduction of the aforementioned protective measure.

Based on the foregoing, there is a need for an absorbent article provided with a protective measure for preventing leakage of low viscosity bodily exudates from the waist opening, while maintaining good stretchability for ease of application, good fit for preventing sagging, good comfort and softness, and good breathability. There is also a need for providing such an absorbent article which can be economically made.

The present invention is directed to an absorbent article having a longitudinal direction and a transverse direction comprising a front elastic belt, a back elastic belt, a crotch region, a waist opening, and a pair of leg openings; the crotch region extending longitudinally between the front elastic belt and the back elastic belt;

The present invention is also directed to manufacturing methods of the above mentioned articles.

As used herein, the following terms shall have the meaning specified thereafter: “Absorbent article” refers to articles of wear which may be in the form of pants, taped diapers, incontinent briefs, feminine hygiene garments, and the like, so configured to also absorb and contain various exudates such as urine, feces, and menses discharged from the body. The “absorbent article” may serve as an outer cover adaptable to be joined with a separable disposable absorbent insert for providing absorbent and containment function, such as those disclosed in PCT publication WO 2011/087503 A.

“Pant” refers to disposable absorbent articles having a pre-formed waist and leg openings. A pant may be donned by inserting a wearer's legs into the leg openings and sliding the pant into position about the wearer's lower torso. Pants are also commonly referred to as “closed diapers”, “prefastened diapers”, “pull-on diapers”, “training pants” and “diaper-pants”.

“Longitudinal” refers to a direction running substantially perpendicular from a waist edge to an opposing waist edge of the article and generally parallel to the maximum linear dimension of the article.

“Transverse” refers to a direction perpendicular to the longitudinal direction.

“Proximal” and “distal” refer respectively to the position closer or farther relative to the longitudinal center of the article.

“Body-facing” and “garment-facing” refer respectively to the relative location of an element or a surface of an element or group of elements. “Body-facing” implies the element or surface is nearer to the wearer during wear than some other element or surface. “Garment-facing” implies the element or surface is more remote from the wearer during wear than some other element or surface (i.e., element or surface is proximate to the wearer's garments that may be worn over the disposable absorbent article).

“Disposed” refers to an element being located in a particular place or position.

“Joined” refers to configurations whereby an element is directly secured to another element by affixing the element directly to the other element and to configurations whereby an element is indirectly secured to another element by affixing the element to intermediate member(s) which in turn are affixed to the other element.

“Film” refers to a sheet-like material wherein the length and width of the material far exceed the thickness of the material. Typically, films have a thickness of about 0.5 mm or less.

“Water-permeable” and “water-impermeable” refer to the penetrability of materials in the context of the intended usage of disposable absorbent articles. Specifically, the term “water-permeable” refers to a layer or a layered structure having pores, openings, and/or interconnected void spaces that permit liquid water, urine, or synthetic urine to pass through its thickness in the absence of a forcing pressure. Conversely, the term “water-impermeable” refers to a layer or a layered structure through the thickness of which liquid water, urine, or synthetic urine cannot pass in the absence of a forcing pressure (aside from natural forces such as gravity). A layer or a layered structure that is water-impermeable according to this definition may be permeable to water vapor, i.e., may be “vapor-permeable”.

“Extendibility” and “extensible” mean that the width or length of the component in a relaxed state can be extended or increased.

“Elasticated” and “elasticized” mean that a component comprises at least a portion made of elastic material.

“Elongatable material”, “extensible material”, or “stretchable material” are used interchangeably and refer to a material that, upon application of a biasing force, can stretch to an elongated length of at least about 110% of its relaxed, original length (i.e. can stretch to 10 percent more than its original length), without rupture or breakage, and upon release of the applied force, shows little recovery, less than about 20% of its elongation without complete rupture or breakage as measured by EDANA method 20.2-89. In the event such an elongatable material recovers at least 40% of its elongation upon release of the applied force, the elongatable material will be considered to be “elastic” or “elastomeric.” For example, an elastic material that has an initial length of 100 mm can extend at least to 150 mm, and upon removal of the force retracts to a length of at least 130 mm (i.e., exhibiting a 40% recovery). In the event the material recovers less than 40% of its elongation upon release of the applied force, the elongatable material will be considered to be “substantially non-elastic” or “substantially non-elastomeric”. For example, an elongatable material that has an initial length of 100 mm can extend at least to 150 mm, and upon removal of the force retracts to a length of at least 145 mm (i.e., exhibiting a 10% recovery).

“Dimension”, “Length”, “Width”, “Pitch”, “Diameter”, “Aspect Ratio”, “Angle”, and “Area” of the article are all measured in a state wherein the article is extended to the Full Stretch Circumference Wi according to the “Whole Article Force Measurement” herein, and utilizing a ruler or a loupe, unless specified otherwise.

“Artwork” refers to a visual presentation to the naked eye, which is provided by printing or otherwise, and having a color. Printing includes various methods and apparatus well known to those skilled in the art such as lithographic, screen printing, flexographic, and gravure ink jet printing techniques.

“Color” or “Colored” as referred to herein includes any primary color except color white, i.e., black, red, blue, violet, orange, yellow, green, and indigo as well as any declination thereof or mixture thereof. The color white is defined as those colors having a L* value of at least 94, an a* value equal to 0±2, and a b* value equal to 0±2 according to the CIE L* a* b* color system.

is a perspective view of an absorbent article () of the present invention, andis a schematic plan view of an absorbent article with the seams unjoined and in its flat uncontracted condition showing the garment-facing surface. The absorbent article () has a longitudinal centerline Lwhich also serves as the longitudinal axis, and a transverse centerline Twhich also serves as the transverse axis. The absorbent article () has a body facing surface, a garment facing surface, a front elastic belt (), a back elastic belt (), a crotch region (), and side seams () which join the front elastic belt () and the back elastic belt (), to form two leg openings and a waist opening.

The absorbent article () may be a belt-type pant as incomprising an absorbent main body () to cover the crotch region () of the wearer, a front elastic belt () and a back elastic belt () (hereinafter may be referred to as “front and back elastic belts”), the front and back elastic belts (,) forming a discrete ring-like elastic belt () extending transversely defining the waist opening. For the belt-type pant, the discrete ring-like elastic belt () may also be referred to as the elastic belt (). For the belt-type pant as in, the front and back elastic belts (,) and the absorbent main body () jointly define the leg openings. For the belt-type pant, the front elastic belt () is the front region (), and the back elastic belt () is the back region (), and the remainder is the crotch region (). While not shown, the absorbent article () may be a uni-body type pant configured such that the outer cover layer of the absorbent main body () and the garment facing layer of the elastic belt () are common. For the uni-body type pant, the portion extending in the transverse direction between the side seams (), respectively, are considered the front region () and the back region (), and the remainder is the crotch region (). For the uni-body type pant, the front region () is considered the front elastic belt (), and the back region () is considered the back elastic belt ().

The absorbent main body () comprises a topsheet, a backsheet and an absorbent material region () disposed between the topsheet and the backsheet. The absorbent main body () may further comprise an outer cover layer () for covering the garment-facing side of the backsheet. The topsheet may be a water permeable substrate. The backsheet may be a water impermeable film. The outer cover layer () may be a nonwoven sheet. The absorbent main body () comprises an absorbent material region () for absorbing and containing body exudates disposed on the absorbent main body (), and an absorbent material non-existing region () surrounding the periphery of the absorbent material region (). The area adjacent the front and back longitudinal end edges of the absorbent main body () comprise the backsheet. The absorbent material non-existing region () may be made of the topsheet and/or the backsheet and/or the outer cover layer () and/or other parts configuring the absorbent main body (). In the embodiment shown in, the absorbent main body () has a generally rectangular shape, left and right longitudinally extending side edges () and front and back transversely extending end edges (). The absorbent material region () may exist through the entire longitudinal dimension of the crotch region and extending at least partly in the front and back regions (,). The absorbent main body () may have a front waist panel () positioned in the front region () of the absorbent article (), a back waist panel () positioned in the back region (), and a crotch panel () between the front and back waist panels (,) in the crotch region (). The center of the front elastic belt () is joined to a front waist panel () of the absorbent main body (), the center of the back elastic belt () is joined to a back waist panel () of the absorbent main body (), the front and back elastic belts (,) each having a left side panel and a right side panel () where the absorbent main body () does not overlap. The absorbent main body () has a crotch panel () positioned between the front waist panel () and the back waist panel ().

The absorbent material region () may comprise an absorbent layer and an acquisition layer. The absorbent layer is the region wherein absorbent materials having a high retention capacity, such as superabsorbent polymers, are present. The absorbent layer may be substantially cellulose free. Superabsorbent polymers of the absorbent layer may be disposed between first and second layers of material immobilized by a fibrous layer of thermoplastic adhesive material. The first and second layers of materials may be nonwoven fibrous webs including synthetic fibers, such as mono-constituent fibers of PE, PET and PP, multiconstituent fibers such as side by side, core/sheath or island in the sea type fibers. Such synthetic fibers may be formed via a spunbonding process or a meltblowing process. The acquisition layer facilitates the acquisition and the distribution of body exudates and may be placed between the topsheet and the absorbent layer. The acquisition layer may include cellulosic fibers.

The absorbent layers may be disposed in plurality in the absorbent material region (). Some portions of the absorbent layers may be configured to have substantially no absorbent material to form a channel or a plurality of channels. Channels may be useful for allowing the absorbent material region () to bend upon swelling with fluids, such that the absorbent article conforms to the wearer's body after swelling and prevent sagging of the article. The channels may also be formed in the acquisition layer, and may be configured to at least partly match the channels of the absorbent layer in the thickness direction.

Referring to, the absorbent main body () may comprise leg cuffs () made of material having high fluid impermeability, and elasticized to provide a barrier along both transverse edges of the absorbent main body (). Such leg cuffs () may be attached to the remainder of the absorbent main body by bonding them to the topsheet at both longitudinal edges of the absorbent main body (), such that at least in the crotch region (), the leg cuffs are in active elasticity to provide gasketing around the leg openings.

The elastic belt () of the article of the present invention acts to dynamically create fitment forces and to distribute the forces dynamically generated during wear. The front and back elastic belts (,) may be joined with each other only at the side edges () to form side seams (), a waist opening and two leg openings. Each leg opening may be provided with elasticity around the perimeter of the leg opening. The elasticity around the leg opening may be provided by the combination of elasticity from the front elastic belt (), the back elastic belt (), and the leg cuffs ().

The longitudinal length of the backsheet and the outer cover layer () may be the same, or may be varied. For example, the outer cover layer () may have a shorter length compared to that of the backsheet, such that the outer cover layer () is devoid where the absorbent main body () overlaps the elastic belt (). By such configuration, the elastic belt may have better breathability. Further, such configuration may provide cost saving. The transverse width of the backsheet and the outer cover layer () may be the same, or may be varied. For example, the backsheet may have a shorter transverse width compared to that of the outer cover layer (). By such configuration, the longitudinal side edges () of the crotch panel (), which make part of the leg openings, may have better breathability. Further, such configuration may provide cost saving.

For the belt-type pant, the longitudinal length LB of the back elastic belt () and the longitudinal length LF of the front elastic belt () may be provided the same, or the back elastic belt () may have a greater longitudinal length LB as in. Referring to, when the wearable article is assembled to form the waist opening and the leg openings, the wearable article () is folded along the transverse centerline Tsuch that the front distal edge () is aligned with the back distal edge (). The front side edge () is also aligned with a portion of the back side edge (). Then the front elastic belt () and the back elastic belt () are joined at the front and back side edges () at the seams (). The front and back proximal edges (), however, may not be aligned to one another. The back proximal edge () may be disposed longitudinally closer than the front proximal edge () relative to the transverse center line Tsuch that the proximal portion of the back side panel () extends toward the crotch panel () of the main body () beyond the front proximal edge (). The side edge of the proximal portion of the back side panel () may not be joined to anywhere and free from attachment. Thus, the proximal portion of the back side panel () provides a buttock cover () (not shown).

The front elastic belt () and back elastic belt () are configured to impart elasticity to the belt (). Referring to, the front elastic belt () and the back elastic belt () may each comprise a laminate, the laminate comprising a plurality of elastic members (F,S) running in the transverse direction, an inner sheet (), an outer sheet (), and one or a plurality of outer sheet fold overs (,) wherein the outer sheet fold over is an extension of the outer sheet material formed by folding the outer sheet material at the distal edge () of the front and back elastic belts or otherwise; wherein the belt elastic members (F,S) are sandwiched between two of these sheets. The front elastic belt () and the back elastic belt () may each be made only by elastic members (S), the inner sheet (), the outer sheet (), and the outer sheet fold overs (,). The belt elastic members (F,S) may extend in the transverse direction to provide a ring like elastic belt () when the front elastic belt () and the back elastic belt () are joined. At least some of the elastic members (F,S) extend in the transverse direction substantially parallel to each other. All of the elastic members (F,S) may extend in the transverse direction substantially parallel to each other. Such an article may be economically made. The front and back elastic belt (,) each may have transversely continuous proximal and distal edges, the proximal edge () being located closer than the distal edge () relative to the longitudinal center of the article. At least 10%, or at least from about 15% to not more than about 70%, of the front and back elastic belts from the waist opening in the longitudinal direction may be a laminate in active elasticity along the entire transverse dimension LW of the front and back elastic belts (,). For each front and back elastic belt (,), the region overlapping the front and/or back waist panel (,) of the absorbent main body () may be removed of its elastic activity. Such region removed of elastic activity is referred herein as the “elastic cut window”, and the remainder of the intact elastic member capable of imparting elasticity is defined as the “effective length of elasticity of an elastic member”.

The tensile stress (N/m) of the entirety of the front and back elastic belts (,), respectively, may be profiled in order to provide the functional benefits of the present invention, such as ease of stretch and application, while also maintaining certain force during wear, to prevent the article from sagging after loading. When the elasticity of the front and back elastic belts (,) are provided by a plurality of elastic members (F,S) running in the transverse direction, the tensile stress may be adjusted by one or more of the following methods; 1) elongation rate of the elastic member (F,S); 2) density (dtex) of the elastic member (F,S); 3) longitudinal pitch of multiple elastic members (F,S); and 4) effective length of elasticity of the elastic member (F,S) in the transverse direction. By elongation, “0% elongation” is meant the original length of the elastic member.

Referring to, the front and back elastic belts (,) may each be divided into multiple zones spanning in the transverse direction and defined by its location from the distal edge () to the proximal edge () relative to the percentage of the seam length LS wherein the distal edge () is considered 0% and the proximal edge () is considered 100%. The multiple zones may be configured to provide different tensile stress, or different functions to the front and back elastic belts (,), respectively. In the absorbent article of the present invention, a waist guard portion WGP is disposed within a location of 25-60% of LS on one or both of the front and back elastic belts (,), the waist guard portion WGP extending towards the crotch region from a closed base line (B) toward an open edge (M), wherein the waist guard portion WGP is partially bonded to the remainder of the front or back elastic belt (,) to define a pocket (P).depicts a waist guard portion WGP on the back elastic belt. The waist guard portion WGP need not span the entire 25% to 60% of LS, but rather is comprised within such dimension. The waist guard portion WGP may be positioned at a dimension of from about 25% to about 50% of LS, or from about 30% to about 60% of LS, or from about 25% to about 55% of LS, or from about 30% to about 50% of LS. Without being bound by theory, by providing the waist guard portion WGP in such dimension on the back elastic belt (), the buttock cleavage of a wearer is effectively covered by the waist guard portion WGP so that low viscosity exudate, such as runny fecal matter or blood, may be effectively drawn into the pocket. Without being bound by theory, by providing the waist guard portion WGP in such dimension on the front elastic belt (), the area matching the pubic bone of a wearer is effectively covered by the waist guard portion WGP, so that low viscosity exudate, such as urine, may be effectively drawn into the pocket.

Referring to, the waist guard portion WGP is explained by utilizing an embodiment provided on the back elastic belt (). The waist guard portion WGP is made by an extension of the outer sheet () extending beyond the longitudinal dimension of the inner sheet (), which extension of the outer sheet () is folded inwardly 2 times in order to encompass a first elastic member (F) and further to provide the waist guard portion WGP in the intended position relative to the side seam length LS. As a result of the 2 folds, the first elastic member (F) is sandwiched between the first outer sheet fold () and the second outer sheet fold (), wherein the first outer sheet fold () constitutes the garment facing side of the waist guard portion WGP, and the second outer sheet fold () constitutes the body facing surface. Referring to, a certain longitudinal dimension from the distal edge of the second outer sheet fold () is bonded to the remainder of the belt, such bonding shown as SWFA, however, leaving some longitudinal dimension unbonded. The position provided most distal of the unbonded region is the closed base line (B), and the common proximal edge of the first outer sheet fold () and second outer sheet fold () is the open edge (M). The waist guard portion WGP is defined as having a longitudinal dimension spanning from the closed base line (B) and the open edge (M), and having a transverse dimension matching the width of the belt to which it is provided. The left and right transverse edges of the waist guard portion WGP are also bonded to the remainder of the belt, such bonding shown as SWFA. The unbonded region thus provided is the pocket (P). The bondings provided to define the area of the pocket (P) are so configured to provide the pocket (P) substantially superposing the backsheet, preferably completely superposing the backsheet. Without being bound by theory, by providing the pocket (P) substantially superposing the backsheet, this prevents low viscosity exudate having entered the pocket (P) from flowing or penetrating out of the pocket (P) towards the waist opening, or the transverse edges.

Referring to, the first elastic member (F) provides the waist guard elastic portion WGEP, wherein elasticity may be imparted by one or more elastic strands, elastic ribbons, mechanically activated nonwovens, or otherwise. The waist guard elastic portion WGEP is defined as having a longitudinal dimension () spanning from the open edge (M) to the distal edge of the first elastic member (F). When the first elastic member (F) is a plurality of elastic strands, the distal edge of the waist guard elastic portion WGEP is the position of the elastic strand which is positioned most distal. There may be 2-10 elastic strands, or from 2-5 elastic strands, or 2-8 elastic strands, or 3-4 elastic strands, or 3-8 elastic strands, or 4-6 elastic strands disposed on the waist guard elastic portion. The longitudinal dimension of the waist guard elastic portion WGEP is smaller than that of the waist guard portion WGP such that a pocket (P) having containment capacity may be provided. The longitudinal dimension of the waist guard elastic portion WGEP may be no greater than about 40 mm, or no greater than about 35 mm, or no greater than about 30 mm, or no greater than about 25 mm, or from 15 mm to about 40 mm, or from about 10 mm to about 35 mm, or from about 10 mm to about 25 mm. In, the pocket (P) has a rectangular shape, however, the pocket (P) may take other shapes by changing the bonding area SWFA such that the closed base line (B) is shaped. For example, the closed base line (B) may be concave or convex toward the pocket (B) to match the wearer's anatomy. The longitudinal dimension of the pocket (P) defined as the shortest distance between the closed base line (B) to the open edge (M) may be from about 20 mm to about 45 mm, or from about 24 mm to about 42 mm.

Referring to, the remainder of the belt superposing the waist guard elastic portion WGEP is defined a correlated portion CP. Namely, the correlated portion CP has the same longitudinal dimension () as the waist guard elastic portion WGEP. The correlated portion CP may be elasticized or may not be elasiticized, wherein the tensile stress of the waist guard elastic portion WGEP is higher than that of the correlated portion CP. The correlated portion CP may be elasticized wherein the tensile stress of the waist guard elastic portion WGEP is at least about 25% higher, or at least about 100% higher than that of the correlated portion CP. Without being bound by theory, such tensile stress difference enables the waist guard elastic portion WGEP to be in close contact with the wearer, while pulling away the open edge (M) from the correlated portion CP, thus opening the pocket (P) towards the proximal side. Thus, the pocket (P) is configured to have good containment capacity. The correlated portion CP may have an elastic cut window such that some portion is elasticized, while the transverse center does not interfere with the opening of the pocket (P). When the waist guard elastic portion WGEP is elasticized by disposing a plurality of elastic strands (F), one elastic strand is disposed from no less than 2 mm to 5 mm away from the open edge (M). Placement of the elastic strand on the very edge of the open edge (M) may be avoided in order to prevent the waist guard position WGP causing irritation to the wearer. The waist guard elastic portion WGEP may be disposed with a plurality of elastic strands (F) with a relatively small pitch between each other. The elastic strands (F) of the waist guard elastic portion WGEP may be disposed at a pitch of no more than about 12 mm, or no more than about 10 mm, or no more than about 6 mm, or between about 2 mm to about 8 mm, or between about 3 mm to about 9 mm, or between about 2 mm to about 6 mm.

The elastic strands (F) for providing the waist guard elastic portion WGEP may be provided in color such that the existence and function of the waist guard portion WGP is clearly communicated to the wearer or caregiver. At least 2 of the elastic strands for providing the waist guard elastic portion WGEP may have a color which is visible from the body facing side of the article. The color may be selected from green, blue, purple, or a combination thereof, in order to be easily recognized, while not being confused with the color of containment. The same or similar color may be used for other elastic strands (S) disposed on the belt to provide a coordinated appearance. For example, those elastic strands on the front waist zone () or the back waist zone () may have the same or similar color.

The waist guard portion WGP may be configured in a certain way relative to the absorbent main body to provide improved function. As mentioned above, the area of the pocket (P) are so configured to provide the pocket (P) substantially superposing the backsheet, preferably completely superposing the backsheet. Referring to, the longitudinal edges of the absorbent main body () may be positioned and bonded between the waist guard portion WGP and the remainder of the belt. This is to avoid having sharp edges of the absorbent main body () on the body facing surface, and also to avoid leakage from the edges. The absorbent main body () comprises an absorbent material region () which may be surrounded by an absorbent material non-existing region (), wherein the absorbent material region () having a greater thickness than that of the absorbent material non-existing region (). The absorbent material region () may partially superpose the area of the pocket (P) to provide at least some absorbent capacity in this region. At least about 3%, or at least about 10% of the area of the pocket (P) may superpose the absorbent material region () toward the proximal edge. Even so, the combined thickness of the waist guard elastic portion WGEP, the correlated portion CP, and the portion of the absorbent main body () sandwiched therebetween may be kept to no more than about 5 mm, preferably no more than about 4 mm. This is so that the thickness of the remainder of the article does not interfere with the opening of the pocket (P) towards the proximal side due to the elasticity of the waist guard elastic portion WGEP. When the absorbent main body () comprises an acquisition system, the acquisition system may be avoided from superposing the pocket (P). In order to provide the waist guard portion WGP relative to the absorbent main body () in the aforementioned way, the distance between the waist opening to the longitudinal edge of the absorbent main body () may be adjusted, namely may be shifted toward the back side or the front side. For example, when the waist guard portion WGP is provided only on the back elastic belt (), the distance between the waist opening to the longitudinal edge of the absorbent main body () may be made shorter on the back side than the front side.

The belt on which the waist guard portion WGP is disposed may be divided into 3 zones spanning in the transverse direction and defined by its location from the distal edge () to the proximal edge () relative to the percentage of the seam length LS wherein; 0% to the distal edge of the waist guard portion WGP is a waist zone (), and the distal edge to the proximal edge of the waist guard portion WGP is a protective zone (), and the proximal edge of the waist guard portion WGP to 100% is another zone. When there is an elastic member disposed at the distal edge or the proximal edge of the protective zone (), such elastic member is considered to be included in the protective zone (). Elastic members may be disposed on the remainder of the protective zone () which superposes the unelasticized area of the waist guard portion WGP. Regardless of the existence of the waist guard portion WGP, elastic members may be disposed on each of the waist zone (), the protective zone () other than the waist guard portion WGP, and another zone.

The waist guard portion WGP may be configured in a certain way relative to a pair of leg cuffs () disposed along both transverse edges of the absorbent main body (), to provide improved function. For the belt comprising the waist guard portion WGP, the leg cuffs () may be in active elasticity at the point intersecting the open edge (M). By providing the leg cuffs in active elasticity in such position, the combined elasticity from the leg cuffs and waist guard elastic portion WGEP may help hold the leg cuffs () and waist guard portion WGP in close contact with the wearer, and further provide additional containment capacity for the pocket (P).

Referring to, when the waist guard portion WGP is disposed on the back elastic belt (), the back elastic belt () may be divided into 3 zones spanning in the transverse direction and defined by its location from the distal edge () to the proximal edge () relative to the percentage of the seam length LS wherein; 0% to the distal edge of the waist guard portion WGP is a back waist zone (), the distal edge to the proximal edge of the waist guard portion WGP is a protective zone (), and the proximal edge of the waist guard portion WGP to 100% is a buttock zone (). The back elastic belt may further have a buttock cover zone (), wherein the longitudinal dimension of the back elastic belt LB exceeds LS. Elastic members may be disposed on each of the waist zone (), the protective zone () other than the waist guard portion WGP, the buttock zone (), and the buttock cover zone ().

When the waist guard portion WGP is not disposed on the front elastic belt, the front elastic belt may be divided into 4 zones wherein: 0-25% is the waist zone (), 25-50% is the distal tummy zone (), 50-85% is the proximal tummy zone (), and 85-100% is the leg zone (). When there is an elastic member disposed at 25% from the distal edge (), such elastic member is considered to be included in the waist zone (). When there is an elastic member disposed at 50% from the distal edge (), or 85% from the distal edge (), such elastic member is considered to be included in the proximal tummy zone ().

When the waist guard portion WGP is disposed on the back elastic belt and not disposed on the front elastic belt, the tensile stress of the protective zone () may be provided higher than the tensile stress of either the back waist zone (), or the buttock zone (). When the waist guard portion WGP is disposed on the back elastic belt and not disposed on the front elastic belt, the tensile stress of the front proximal tummy zone () may be provided higher than the tensile stress of any of the front waist zone (), the front distal tummy zone (), or the front leg zone (). The tensile stress of the front proximal tummy zone () may be higher than the tensile stress of any other zone, either in the front or the back. When comparing all of the zones of the front elastic belt and the back elastic belt, the tensile stress may be provided greatest in the order of: the front proximal tummy zone (), followed by the protective zone (). Without being bound by theory, such profiling of the tensile stress per zone is believed to provide the article of the present invention with a shaped elastic belt () that conforms well to a human body, such as in, particularly to a lower torso of a child of less than 36 months of age, and therefore provide good fit and comfort to the wearer, without compromise of sagging prevention or leakage prevention. Namely, the front proximal tummy zone () is subject to high tensile stress such that the article may be anchored against the wearer's trochanter, while leaving more area for the buttock zone () to accommodate the wearer's buttock.

Referring to, the elastic belts of the present invention may be made by a relatively simple structure comprising no more than the inner sheet (), the outer sheet (), the first outer sheet fold (), the second outer sheet fold (), and the first and second elastic members (F,S) encompassed within these layers. Any portion of the elastic belt comprising the waist guard portion WGP may be made by less than 6 layers, or made by 3-4 layers, and in a thickness of no more than about 5 mm, or no more than about 4 mm. Providing the belt structure simple and relatively thin is advantageous in maintaining breathability and softness of the belt. Further, the elastic belts may be made by elastic strands commonly used in the art having a density of no more than 940 dtex. Certain zones of the belt may be disposed of elastic bodies having a density of no more than about 500 dtex, thus providing a soft fit. Elastic bodies having a density of no more than about 500 dtex may be disposed on one or more of the waist zone () or the front leg zone (). Without being bound by theory, it is believed that elastic bodies of relatively low density impart an easy initial stretch experience when stretch opening the article (), while maintaining a good fit during wear. The article of the present invention may be provided with a protective measure for preventing leakage of low viscosity bodily exudates from the waist opening, while maintaining good stretchability for ease of application, good fit for preventing sagging, good comfort and softness, and good breathability. The present article may have a Waist Circumference Force according to the Whole Article Force Measurement herein of no more than about 9N, or no more than about 8N.

In the present invention, at least one of the inner sheet (), the outer sheet (), or the outer cover layer () may further comprise a plurality of apertures, wherein the individual aperture may be in the shape of an oval, or polyhedron, while having an aspect ratio of no more than about 3, or no more than about 2.5. The individual aperture may have a transverse dimension APT of at least about 0.4 mm, or from about 0.4 mm to about 2.0 mm, and a longitudinal dimension APL, wherein APT is at least about 10% greater than APL. Further, the individual apertures may be spaced apart from each other with a longitudinal pitch DFof no more than about 5 mm, and APL is not larger than 50% of DF, or APL is from about 12% to about 30% of DF. Apertures of such size, shape, and spacing may be visible to the naked eye on the garment-facing surface. When apertures are provided on the outer sheet (), this may connote breathability and high quality of the gathers made by the contraction of the elastic members of the elastic belt (), even when the gathers are in contracted state. By providing apertures on the outer sheet () and the outer cover layer () and further coordinating the patterns of apertures, this may enhance integral appearance of the elastic belt () and absorbent main body ().

Referring to, even when the back elastic belt () comprises a waist guard portion WGP, the remainder of the back elastic belt (), and particularly the garment facing surface of the back elastic belt (), may be maintained in a simple structure. This enables the article to have other functions that are desired of a pant type absorbent article, such as having a disposal tape attached to the garment facing surface of the back elastic belt (). Accordingly, the absorbent article may be devoid of fastening means.

Referring to, the steps for making the absorbent article of the present invention is explained, utilizing an embodiment wherein the back elastic belt () comprises the waist guard portion WGP. While only the back belt is shown in, the waist guard portion WGP may be made in the same way on the front elastic belt (). Further, the front and back elastic belts may be formed from the same continuous first and second sheets (C,C). The elastic belts of the present invention may be made by a process comprising the steps of providing 2 folds for the outer sheet () and keeping the elastic belt () soft and relatively thin. The process comprises introducing elastic strands (F) for the waist guard elastic portion WGEP by the first fold (), configuring the waist guard portion WGP by the second fold (), and configuring a pocket (P) by bonding certain portions of the first and second fold (,) to the remainder of the back elastic belt () or the back waist panel (,). The main differences compared to methods for making articles devoid of the waist guard portion WGP include; providing the outer sheet () in longer longitudinal dimension of the article, or wider dimension in the CD direction, and having an additional step of providing 2 folds of the outer sheet (), rather than 1 fold. Such differences may be effected conveniently by changing the upstream of currently available methods for making a pant-type article. This enables change over of making the absorbent article of the present invention from those devoid of the waist guard portion WGP relatively easy. The manufacturing method of the present invention is described in further detail below.

Referring to, the present method is directed to providing a waist guard portion WGP to at least one of the front elastic belt () or the back elastic belt () by minor additions and modifications to currently available methods for making a pant-type absorbent article.specifically describes a method for making a belt-type pant. Namely, referring to, an additional first folding step is added to the upper flow of the process. The first folding step as inintroduces the first elastic strands (F), and a second folding step as inconfigures the waist guard portion WGP. The method enables using the same number of elastic strands for the belt, compared to products devoid of the waist guard portion WGP, while also enabling manufacture at a similar line speed. The line speed may be at least about 200 meters per minute, or at least about 250 meters per minute, or at least about 300 meters per minute, or at least about 350 meters per minute, or at least about 400 meters per minute.